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May 1-5 2017
No time to work on the project as I catch up with real work! Plus I
still need to get the car back from the trimmers...
May 6-19 2017
Build Time Today: 40 hours
Total Build Time: 260 hours
I haven't had a chance to update the blog in a while, but this is what I
have been working on the last few weeks:
The car came back from the trimmers with the leather, carpets and
speakers having been installed...
First job was to finish the Audio install - I installed the Amplifier
behind the driver seat, and ran the wires for power, ground and
speakers.. I am using a DSP amp that will work off bluetooth from my
phone/tablet, so there will be no 'head unit' installed... The speakers
were installed in the front passenger panels, and the tweeters have been
left off till later (will go on the dash face)...
I then spent time finishing up the wiring - I was able to procure the
required terminals during my trip to finalize the relay rail and fuse
box... Wires were checked, terminals crimped on, and all the wiring was
secured... While working on the wiring, I also got the wiring for the
VRH installed - this involved making my own sub loom - and running it
from/to the battery, relay rail, switch area, compressor and tank
areas... Finally, all the wiring in engine bay was resolved - all non
required wires in the Ultima loom were cut and tied away (the engine
loom will have these connections), and I also wired in all the
connections for the fans (AC, Extra both sides), LP pump, AC pressure
switch, fuel gauge, and ran wires for the reverse camera and parking
sensor power...
Next I installed the center GRP - again with help from the wife :) The
center GRP was put on the chassis and the bolts tightened up.. I then
drilled for the rivet holes that hold the GRP to the top of the engine
panel chassis rail, and the panels were riveted together.... Finally,
the back face of the GRP was covered with gold heat insulation to help
keep the passenger cabin a little cool...
I then started work on installing the fuel system - all the fuel pipes
made before were installed, along with the LP pump, filters, HP
pump/surge tank unit, regulator, and fuel pressure sensors... All the
fittings were first coated in a fuel-lube sealant to prevent leaks, and
everything was snugged up... The surge tank was also covered in gold
insulation, and the unit installed on the center GRP which has been
pre-drilled for the bobbins... This took quite some time because two
pipes had to be made, tested and insulated, and all the fittings had to
be individually coated in the sealant before fixing... The fuel system
is now ready for testing (for leaks and pressure setting)
I installed the AC hoses, drier, drier pressure sensor, and now the AC
system is ready for its first round of testing (for leaks)... I made a
'compressor pipe' to connect the two compressor fittings to one another
to close the AC system, and pressure tested in using a vacuum pump...
The pump shows a slight leak in the system - so that will need to be
figured out and rectified in the future...
I then worked on the doors - the central locking kit needs to be
installed... I have a similar kit as last time, but am unable to get the
brackets to fit correctly with the actuators in the limited space inside
the doors... Thus I need to make my own brackets... I did this by using
the AB bracket as a template, and then made new sturdier brackets that
hold the actuator OVER the door mechanism... It appears to be a lot of
solid (and more weight) but should do the job nicely... I also slightly
modified the AB supplied door buttons to make them slightly longer, so
that the door mechanism can be engaged better... The interior of the
doors was painted black using tough black paint, and the all the door
hardware was installed - lock mechanism, interior door lever and
exterior button...
Finally, I worked on installing the various VRH parts - all the air
fittings have to installed on the compressor, drier, tank and manifold
valve, and then those pieces need to be secured in the car (luggage pod
and behind pax seat)... I had to build a stand for the compressor to
secure it first, and then installed all the fittings using plenty of
Teflon tape for a tight fit... Finally, I ran the air tube between the
parts to get the system ready on the air inlet side - now only need to
run lines for the outlet to the dampers and connect that...
May 20-31 2017
Build Time Today: 20 hours
Total Build Time: 280 hours
Another cumulative update - it seems easier to do this than an everyday
blog post since not much is being done...
First order of busines was finishing the VRH system - the outlet lines
from the manifold to the dampers were run, with T-pieces to split the
front and rear to both left and right sides... Once the piping was done,
I had to finish the electrical connections and jerry rig a test - the
unit was switched on, and the front and rear were tested to see if they
work off the ground - and success!
Video of test
Once the VRH was functional, I went back to the AC system - some head
scratching and testing with foam/pressure pump did not show any leaks in
the pipes/connections... I then tested the manifold and there appears to
be a small leak in the gauge set! ARGH! Looks like I will need to buy
another manifold gauge first and then come back to test the AC...
I then started work on the side view mirrors - similar to last time, the
housing needed to be trimmed to allow the glass to move uninterrupted...
Once trimmed, the housing was painted black, and the motor assembly
wired and installed...
I then started to prep for the first electrical loom test - all the
switches, lights, accessories, mirrors, washer/wiper, central locking
units, alarm, etc were connected, and all connections were checked to
make sure they were either connected, or covered up to prevent any
shorts... The battery was connected, and everything looked over to make
sure there was no accidental grounding... I tested the horn and hazard
(which should work with ignition off) and they work! The ignition was
switched to ON, and other items tested - side lights, drl, low beams,
high beams, turn, washer/wiper, central locking motors, and immobilizer
system were all tested - and all appear to work just fine! Once
satisfied with everything, all the items were disconnected and repacked
away.
I also spent time ziptieing all the wiring in the dash area to make
space for the AC vents (under dash vents) - the vents were installed
between the dash chassis rail and AC blower unit, and the AC hose
installed...
Next, I decided to prepare the doors for trimming... I will be using the
full windows this time, so there is a window support that fits into the
top door panel - I wanted to drill this hole before trimming the door so
that the leather is not damaged in the future for this... The dash GRP
and windscreen were temporarily put together, and the doors offered up
next to them to see where the window support needed to be installed..
Once I had the location, the doors were drilled for the supports, and
then sent to the trimmers for interior work... All the hardware (central
locking kit, handle, window support) will be installed after trimming...
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